Basics Automatic Mode Control V1.00 En

PCS 7 System Course

SIMATIC PCS 7 Basic Automatic Mode Control Training Documentation, V1.00, ST-PCS7SYS 10 - 1

Content 10 10 Basics Automatic Mode Control ............................................................................ 3

10.1 Learning targets ..................................................................................................................... 3

10.2 Setting the Auto/Manual mode by program ........................................................................... 4 10.2.1 Logic for control output (open/close command to valve) ....................................................... 4 10.2.2 Demonstration with push buttons and switches .................................................................... 5 10.2.3 Examples for controlling the Auto / Manual mode by program .............................................. 5

10.3 Task and checkpoint .............................................................................................................. 6

10.4 Sequential control with SFC .................................................................................................. 7 10.4.1 SFC Charts ............................................................................................................................ 7 10.4.2 Elements of a Sequence ........................................................................................................ 9 10.4.3 Close cooperation ................................................................................................................ 10 10.4.4 Interconnections between CFC and SFC ............................................................................ 11 10.4.5 Initialization, Processing and Termination ........................................................................... 14 10.4.6 Example ............................................................................................................................... 15 10.4.7 SFC in test mode ................................................................................................................. 15 10.4.8 Task and checkpoint ............................................................................................................ 16 10.4.9 Operating state logic for sequencers (sequencer OSL) ...................................................... 16 10.4.10 Operating state logic for a SFC (SFC OSL) ........................................................................ 17 10.4.11 External View ....................................................................................................................... 18 10.4.12 Task and Checkpoint ........................................................................................................... 18 10.4.13 Add a new sequencer into the chart and setup the properties ............................................ 19 10.4.14 Default behavior of an SFC ................................................................................................. 19 10.4.15 Sequencers reacting on changes of state ........................................................................... 21

10.5 Sequences on the OS .......................................................................................................... 22 10.5.1 Preparation in the ES ........................................................................................................... 22 10.5.2 Steps of SFC operation in Runtime ..................................................................................... 23 10.5.3 SFC MultiChart Control ........................................................................................................ 24

10.6 SFC type .............................................................................................................................. 27

10.7 Task and checkpoint ............................................................................................................ 28

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SIMATIC PCS 7 Basic Automatic Mode Control 10 - 2 Training Documentation, V1.00, ST-PCS7SYS

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10 Basics Automatic Mode Control

10.1 Learning targets

Siemens AG 201210 - 2

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Basics Automatic Mode Control

Learning Targets

The participant will learn about

the general concept of automatic mode control

The participant will be able to

have devices controlled dependend of states of other devices

have devices controlled by sequential controls

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10.2 Setting the Auto/Manual mode by program

10.2.1 Logic for control output (open/close command to valve)

The diagrams below show the logic of a VlvL block regarding the control signal Ctrl

and the Auto / Manual mode.

In these simplified diagrams the influence of other signals like Local mode, Out of Service, forcing, interlocks and feedback error are ignored.

The red arrows represents the Boolean value true (digital: 1) that is send from the OS, by clicking the related button (with OK) to the related input of the block in the AS.

After processing this value by the block program, the input value is put back to false (digital: 0).


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Setting the Auto / Manual mode by program

Logic for control output (open / close command to valve)

CtrL

VlvL

Logic for

Auto / Manual

mode

OpenAut

OpenMan

CloseAut

CloseMan

S

R

1

Feature.Bit4:

0 = Button mode

1 = Switch mode

Output driver

PIQ

Output module

Simplified diagram for explaining the logic


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Logic for Auto / Manual mode

Logic for Auto / Manual mode

ModLiOp

AutModLi

AutModOp

ManModLi

ManModOp

S

R

1

Feature.Bit4:

0 = Button mode

1 = Switch mode

Simplified diagram for explaining the logic

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10.2.2 Demonstration with push buttons and switches

Below 2 VlvL blocks of R310 with connections to signals from the Signal Box:


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Demonstration

VlvL

OpenAut

CloseAut

Button mode

ModLiOp

AutModLi

ManModLi

V311

T4

S1

T3

T2

T1

VlvL

OpenAut

CloseAut

Switch mode

ModLiOp

AutModLi

ManModLi

V312

S2

S4

S3

T = push button

S = Switch

10.2.3 Examples for controlling the Auto / Manual mode by program


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Examples for controlling the Auto / Manual mode

by program

ModLiOp

AutModLi

0

1

ModLiOp

AutModLi

ModLiOp

AutModLi

0

1

0

1

t

ModLiOp

AutModLi

2

3

4

5 6 7

1

8

1. The gray rectangles represent any block offering one or two outputs that can be used to control the mode.

2. When ModLiOp has value 0, then the mode can only be controlled by operator on

the OS.

3. The mode is controlled by the source of the connection

4. When the source changed from 0 to 1: Auto mode, operator can not change to Manual. When the source changed from 1 to 0: remains in Auto mode, but operator can change to Manual.

5. Operator controls the mode.

6. Auto mode, can not change to Manual

7. Switching back to Manual mode, operator can not change to Auto.

8. Operator controls the mode.

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10.3 Task and checkpoint

Task: Auto mode for the material tanks

Goal

One common switch on the OS to set the outlet valves and outlet pumps of the material tanks in Auto mode.

When in Auto Mode, then the outlet valve and outlet pump of a material tank must follow up the demand for the material: opening and starting when a dose valve has opened.

Checkpoint


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Task: Auto mode for the material tanks

Checkpoint

Consider

a way to have the Auto mode of all devices of D210 and R310 set by a single operation, leaving the devices in such a state, that the operator can switch back to Manual mode if required.

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10.4 Sequential control with SFC

The sequential function chart (SFC) is a sequential control system executed in stages which, depending on certain conditions, advances from one state to the next.

A sequential control system controls functions, such as CFC charts, via mode and state changes, and processes them selectively.


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Sequential control with SFC

SIMATIC Manager

STEP 7

STEP 7 - tools

PH IEAPO

CFC SFC

WinCC

SFC Visualization

AS OS

ES

10.4.1 SFC Charts


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Sequential control with SFC SFC charts

Configuration limits of the SFC

Sequencers per SFC chart 8

Steps per sequencer 2 - 255

Instructions per action 50

Transitions per sequencer 1 - 255

Conditions per transition / start condition 16

A SFC chart consists in maximum 8 sequencers for different states of the sequential control system (e.g. default: Run, Hold, Resume, Abort...or customized: Heating, Cooling, Dosing, Draining, etc.). An SFC chart is assigned uniquely to a CPU and is also executed completely on this CPU.

See [103] PCS 7 V8.0 Engineering System - 12_2011, 8.12.8 for more detail

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Run Sequence

The runtime properties of an SFC chart or SFC instance determine how the SFC is included in the chronological execution sequence within the overall structure in the CPU. These properties determine the behavior of the target system with respect to response times, dead times, or the stability of time-dependent structures, such as control loops.

The insertion in the Run Sequence is done using the Predecessor for Insert Position.

The SFC chart is represented by a single object like a chart or as a part of a runtime group like a block:


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SFC charts

Run Sequence

Single object like a chart

Part of a runtime group

like a block

It depends on the structure of your project!

Insufficient runtime properties of an SFC chart are a typical beginners mistake caused by a wrong default position Predecessor for Insert.

The cyclic operation interval of blocks controlled by an SFC must not be larger than the cyclic operation interval of the SFC itself.

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10.4.2 Elements of a Sequence

A newly created sequencer (menu command Insert > Sequencer > ...) is inserted at a selected position in the SFC in its initial state consisting of an initial step, transition and final step.

In its initial state, the new SFC consists of one sequencer. You create each sequencer in its own working window.

A tab is created for every working window at the bottom of the screen. The tab shows the name of the sequencer (for example, RUN or SEQ1). You can switch to the individual sequencers using these tabs.

A toolbar Element bar offers the elements to build up a sequence.


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Elements of a sequence

Tabs represent sequencers

Element bar

Step

Transition

Step

Transition

Step

Transition

Loop

backwards

Step and Transition

Parallel

branch

Alternative

branch

Jump

Lower

branch line

Upper

branch line

See [304] SFC for SIMATIC S7 - Programming and Operating Manual - 12_2011, 11.2 for more details about the sequencer topology.

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10.4.3 Close cooperation

There is a close cooperation between SFC and CFC:

Sequences will not have access to the process signals by their own.

Every access is to be configured in relation to existing function in CFC charts.

Controlling

Controlling devices in the process is to be done through the control blocks in CFC. In general the Auto mode and its related input to control is being used. For a VALVE block the input to be used is AUTO_OC. The VALVE block will have the actual connection to the process through the output driver.

Monitoring

Monitoring the process (in general as a feedback from an earlier step) is done through a block for monitoring the value, using a connection to the related input driver.


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Close cooperation between SFC and CFC

SFC CFC

Open command in Auto mode

Valve is closed

Process value of level monitoring

Move

In CFC, an SFC access can be moved using ALT-drag.

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10.4.4 Interconnections between CFC and SFC

Interconnection to APL blocks in a Transition


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Interconnection to APL blocks in a Transition

2

1

43

5

1. Open the Transition properties (Double click). There is a (possibly empty) list of conditions arranged in boxes.

Each line represents a condition. A maximum of 16 conditions per transition are possible. They are logically linked (default logic: AND).

Each condition consists of a left address, an operator (that you can select from a list box), and a right address.

By clicking the "Go To" button, you can jump to the point of use of the address in whose edit box the text cursor is located (for example, to the CFC chart with the block I/O that is the address of this statement.

2. The "Browse..." button opens a dialog box where you can select an address for the edit box of the condition where the text cursor is located.

3. Navigate to the required block to get the corresponding I/Os displayed.

4. Select the desired block I/O.

5. In case of APL blocks with structures as I/O data type, it is necessary to open the structure. Only a single structure element can be linked. An additional dialog offers you the structure element to be selected.

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Interconnection to APL blocks in a Step


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Interconnection to APL blocks in a Step

2

4

35

1

1. Open the Step properties (Double click). There is a (possibly empty) list of commands arranged in boxes.

Each line represents one statement. You can make up to 50 statements.

Each statement line consists of the following elements:

The button with the line number for selecting the line

The radio button that you can use to select the statement as an OS comment

An edit box for the left address, the operator, and the edit box for the right address

If the text cursor is located in an address box, the shortcut menu displays only the functions needed for editing the contents.

2. The "Browse..." button opens a dialog box where you can select an address for the edit box of the statement where the text cursor is located.

3. Navigate to the required block to get the corresponding I/Os displayed.

4. Select the desired block I/O.

5. In case of APL blocks with structures as I/O data type, it is necessary to open the structure. Only a single structure element can be linked. An additional dialog offers you the structure element to be selected.

Accesses to CFC blocks can also be modified in the relevant CFC chart. This modification, however, is restricted to "rewiring" SFC accesses; in other words, moving the access to another block I/O (with + Drag-and-Drop).

Do not write any values to outputs of blocks and charts (CFC and SFC). Generally, these are overwritten again by the processing of the block or chart.

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Options for to editing addresses in a step

Drag the block inputs/outputs from CFC charts directly to the address box. Resize and arrange the windows of CFC / SFC charts for this purpose.

In the addresses, you can enter accesses to CFC block inputs/outputs whose block does not yet really exist in the CFC chart. These statements are displayed in the statement line on a yellow background and are set up as textual interconnections.

Regardless of the selection and application of changes, all completed lines can be copied and reinserted in any type of actions of other steps at another line.


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Interconnection to APL blocks in a Step Options for adress editing in a step

Drag&Drop

Textual reference

Line buttons with context menu

Statement as an OS comment

Filtering the I/Os in the Browse Dialog


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Filtering the I/Os in the Browse Dialog

Double click to sort

Enter a text to identify

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10.4.5 Initialization, Processing and Termination

In the properties of a step, there are 3 sections where you can enter the actions/commands:

Initialization

If actions have been configured here, they will be executed only once: at transition from the previous step to this step.

Processing

If actions have been configured here, they will be executed during every program cycle, as long as the condition for transferring to the next step is not completed.

Termination

If actions have been configured here, they will be executed only once: at the transition from this step to the next one.


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Intitalization, Processing and termination

Step activeStart Trans 2

Stop Trans 2

cycle

Transition fulfilled

See [304] SFC for SIMATIC S7 - Programming and Operating Manual - 12_2011, 15.3.6.2 for more details

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10.4.6 Example

Next diagram can be used for a demonstration in configuring a SFC chart:


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Example

START

L33

SP=70

H67

SP=50

L53

SP=30

L32

END

70

50

30

SP_EXT

PV_IN

t

Step enabling condition:Process value PV_IN less than 33?

Step enabling condition:Process value PV_IN greater than 67?

Action:Set setpoint SP_EXT to 70

Linear sequence

Conditions in transitions

Actions in steps

Test

Start step

10.4.7 SFC in test mode

In SFC test mode a operating/status bar is displayed for monitoring and controlling. The various step control modes change the behavior of the SFC when passing control from active steps to successor steps:


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SFC in Test mode

Control mode

Operating state

TT or CT and CCT/T and C

TransitionTransition or Confirmation by UserTransition and Confirmation by UserConfirmation by User Step specific Control by operator

Operator confirmation

button

Selection of the step

control mode

Step Control Modes

Operator commands

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10.4.8 Task and checkpoint

Task: First sequence for R310

Goal

A first short sequence for dosing one material and to learn proper switching between manual and automatic mode.

Checkpoint


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Task: First sequence for R310

Checkpoint

What has to be changed in the sequence

if the valve would be in button mode instead switch mode (Feature bit.4)?

10.4.9 Operating state logic for sequencers (sequencer OSL)

The operating state logic of the sequencer is defined by the diagram of the state changes.


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Operating state logic for sequencers (sequencer

OSL)

States exited due to

commands

Operator commands

Implicit state changes

triggered by SFC

See [304] SFC for SIMATIC S7 - Programming and Operating Manual - 12_2011, 15.2.5.5 for more details

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10.4.10 Operating state logic for a SFC (SFC OSL)

Diagram of state changes

The diagram below shows the changes of states of a SFC.


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Diagram of state changes

States that are exited

through events

Transition states that are

implicitly exited

States applied from OSL

for SFC V5.x

Events: Commands / Conditions /

External Signals / Internal Signals

Event: Error

Results applied from OSL

for SFC V5.x

Implicit transitions that are

triggered from SFC, if the active

sequencer has been processed to

completion or if there is not

sequencer to process.

The sequencer OSL is executed independent of the SFC-OSL when a sequencer is processed. This means that the sequencer has a state which differs from the SFC state. For example, the state of the SFC OSL can be "Holding", whereas the state of the sequencer OSL is "Run" (due to the processing of the sequencer to the "Holding" state). The processing of the sequencer OSL is subordinate to the SFC OSL. This means that the state change in the SFC OSL usually effects the state change in the sequencer OSL.

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10.4.11 External View


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External view

Commands and operating

states

Provide information about states

and modes to other blocks

Execution options

Operating modes

Every SFC has an external view that is displayed by the CFC editor.

On the left parameters for controlling the states, modes and more by SFC steps and connections to blocks in CFC charts.

On the right parameters representing states, modes and more information to be used in SFC transitions and for connections to blocks in CFC charts.

The inputs need different types of values / static or dynamic (edges).

See [304] SFC for SIMATIC S7 - Programming and Operating Manual - 12_2011, 12.3.1 for more details

10.4.12 Task and Checkpoint

Task: Complete sequence for R310

Goal

A sequence for dosing and heating a mixture of the 3 materials

Checkpoint


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Task: Sequence for R310

Checkpoint

What happens

during a dosing step, when the command Hold is executed?

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10.4.13 Add a new sequencer into the chart and setup the properties


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Changes of state

Add a new sequencer into the chart

Insert a new sequencer at the corresponding

position

Define the start conditions basing on the SFC OSL

Assign a priority for the case that several

sequencers fulfill their start condition at the

same time

10.4.14 Default behavior of an SFC

By default a SFC contains a single sequencer with the default name RUN.

Start


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Default behavior of an SFC Start

The state RUN is the start condition for the sequencer

called RUN.

When the SFC is started (button Start) for the first time, the first state change will be from IDLE to STARTING.

When the RUN sequencer is the only one, nothing will react on the state STARTING, so the next program cycle the state will change from STARTING to RUN.

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Hold

When during the execution of the RUN sequencer, the SFC is held (button Hold), the state change will be from RUN to HOLDING.

When the RUN sequencer is the only one, nothing will react on the state HOLDING, so the next program cycle the state will change from HOLDING to HELD.


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Default behavior of an SFC Hold

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10.4.15 Sequencers reacting on changes of state

The following picture illustrates the relationship between sequences and operating states.


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Sequencers reacting on changes of state RUN > Holding > Held

Sequencer RUN

Start condition RUN

Sequencer Holding

Start condition Holding


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Sequencers reacting on changes of state RUN > Holding > Held

Sequencer RUN

Start condition RUN

Sequencer Resuming

Start condit. Resuming

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10.5 Sequences on the OS

10.5.1 Preparation in the ES

Block icons for SFCs are generated automatically during OS compilation always.

As an additional option to the OS you can use SFC Visualization.

It allows you to monitor and control SFCs on the OS in a very similar way as in SFC editors test mode.


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Sequences on the OS

Compilation and Block Icons

Block icon for SFC

OS compilation

Create / update block icon mechanism

Compilation

At OS compilation, have the proper check box set, which will allow you to have all the relevant information transferred to the OS, including the creation of the pictures:

Block icons

In a similar way to OS relevant blocks in CFC, there can be representatives of SFC charts being installed in pictures.

User defined buttons

In Graphics designer: Use a Dynamic Wizard to link a button with an SFC visualization object.


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Operating SFC in Runtime Steps in ES

In Graphics designer: Use a Dynamic Wizard to link a button with an SFC visualization object.

User-defined button

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10.5.2 Steps of SFC operation in Runtime


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SFC operation in Runtime

Predefined button in the 2nd key set

User-defined button

User-defined button

Block icon

SectionOverview

Faceplate

SFC browser


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SFC operation in Runtime

Separate windows

Sequencer properties and start condition in

runtime

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10.5.3 SFC MultiChart Control

A SFC MultiChart Control allows you to:

overview several sequences in one picture

browse to the Section and Overview window of a SFC

operate a SFC using buttons on the control

Configuration in Graphics Designer


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SFC MultiChart Control Configuration in Graphics Designer

1

2

3

4

1. In the Object Palette, click the Standard" tab. Select the object Control in the list.

2. Place the mouse pointer at the position in the picture where you want to insert the control. The mouse pointer changes into a crosshair with an object symbol attached.

3. Drag the control to the desired size with the mouse.

4. A list offering all registered ActiveX controls is opened. Select the entry PCS 7 SFC Multichart Control.

The insertion process for the selected control is finished.

If you do not stretch the frame to its complete size, not all the columns will be visible. In this case, a horizontal scroll bar is inserted to enable you to scroll through the contents in the visible area during runtime mode.

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SFC MultiChart Control Properties

Double click

Open the SFC browser

5

6

7

8

5. Double-click the SFC MultiChart Control. The "Properties" dialog box opens.

6. Open the "General" tab and assign the desired SFCs to the control or delete them from it.

7. Open the SFC browser.

8. Select the desired SFC and then close the dialog box with "OK". Repeat this procedure for every SFC that you want to include in the SFC MultiChart Control. A row is inserted for each SFC. This row includes the columns that provide SFC information in runtime mode.

In the Runtime Window


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SFC MultiChart Control in Runtime

Access to the selected SFC

Direct jump to the step in

the faceplate

Boxes for mode controlling

Operating the selected SFC

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SFC MultiChart Control in Runtime

SFC aborted

Waiting for Reset or Start command.

See [305] SFC Visualization - Programming and Operating Manual - 12_2011, 5.13 for more details

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10.6 SFC type

The SFC chart is able to use direct access to addresses in CFC (block I/O).

SFC charts can be edited independently of each other.


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SFC type

SFC CFC

SFC type SFC instance placed into a CFC chart

A SFC type is created beforehand in a chart folder (in library or directly related to AS system).

Steps and transitions will have access to the SFC type its own interface.

Instances

An SFC instance is derived from an SFC type and initially has properties identical to those of the SFC type. You have an executable sequential control system only after interconnecting the SFC instance with blocks and signals of basic automation in CFC charts.


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SFC type

SFC CFC

SFC type SFC instance placed into a CFC chart

By default, the interface of a SFC type is the same as the SFC external view, extended by a number of SFC type specific parameters. Additionally, the user can configure more parameters to create the application specific interface (characteristics).

BATCH

SFC types can be configured to represent an Equipment Phase in a SIMATIC BATCH application.

See [304] SFC for SIMATIC S7 - Programming and Operating Manual - 12_2011, 4.5.2 for more details

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10.7 Task and checkpoint

Task: Holding and resuming

Goal

Preventing material flow when the sequence is held

Checkpoint


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Task: Holding and resuming

Checkpoint

What else could be done in probably more

sequencers to this SFC?

Task SFC Objects

Goal

Have additional ways to monitor and control the progress of the sequence changes of state

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